Vehicle load warning system

ABSTRACT

A load warning system for use with a vehicle having a load-support portion, a frame, and a vehicle-support portion movably coupled to the frame. The system has an engagement portion mountable to the vehicle-support portion or the frame and is movable therewith as a unit. A load indicator is mountable to the other one of the vehicle-support portion or the frame, and is spaced apart from the engagement portion when in a first position. The load indicator moves to a second position and engages the engagement portion when the frame moves a selected distance in response to the load applied to the load-support portion. The load indicator provides a signal upon being moved to the second position. A warning indicator is coupled to the load indicator and provides an improper load warning to a user in response to the signal from the load indicator.

CROSS-REFERENCE TO RELATED APPLICATION(S)

The present application claims priority from U.S. Provisional PatentApplication No. 60/459,699, filed on Apr. 1, 2003, which is herebyincorporated in its entirety by reference thereto.

TECHNICAL FIELD

The present invention is directed to load warning systems, and moreparticularly to load warning systems for vehicles.

BACKGROUND

Vehicles, such as trucks, typically have maximum load ratings set by thevehicle manufacturer. Many vehicles have payload areas that can beloaded with a payload that could exceed the maximum load rating. Thepayload areas can also be improperly loaded with a payload even thoughthe payload doesn't exceed the maximum load rating for the vehicle. Forexample, a payload below the maximum load rating could be located toofar to one side or too far to the rear, thereby changing the handling orsteering characteristics of the vehicle. It is highly desirable toprovide a warning system that indicates when a vehicle is improperlyloaded.

Prior systems have been designed to accurately measure the payloadweight or axle weight. Most of these systems use load cells to supportthe weight and provide an electrical signal indicative of the weight.Some systems have relied on the deflection of the vehicle's suspensionto provide an indication of load. As an example, U.S. Pat. No. 3,531,766to Henzel discloses such a sensing system for overload indication. U.S.Pat. Nos. 4,789,033; 5,522,468; and 6,259,041 B1 to Dohrmann showvarious systems that translate suspension travel into motion that can bemeasured. The sensor output is sent to a display unit that gives anindication of weight. These prior art systems, while detecting weight,have limitations in determining or detecting improper load conditions ina vehicle.

SUMMARY

The present invention provides a load warning system that overcomesdrawbacks experienced in the prior art and that provides additionalbenefits. Under one aspect of the invention, a load warning system isprovided for use with a vehicle. The vehicle has a load-support portionadapted to receive a load thereon. A first portion of the vehicle, suchas a frame, is coupled to the load-support portion. A second portion ofthe vehicle, such as an axle or suspension system, is movable relativeto the first portion upon application of the load onto the load-supportportion. The load warning system has an engagement portion mountable toand movable with the one of the first portion or second portion of thevehicle as a unit.

A load indicator is mountable to the other one of the first portion orsecond portion of the vehicle. The load indicator is configured to bespaced apart from the engagement portion and to be in a first positionwhen the load on the load-support portion is less than a maximum load.The load indicator is also configured to engage the engagement portionand move to a second position when the load on the load-support portionis greater than a maximum load. The load indicator provides a signalupon being moved to the second position. A warning indicator is coupledto the load indicator to receive the signal and to provide an overloadwarning to a user upon receiving the signal.

Under another aspect of the invention, a load warning system has anengagement portion movable with a vehicle's frame or a vehicle-supportportion. A load indicator is coupled to the other one of thevehicle-support portion or the frame. The load indicator is spaced apartfrom the engagement portion when in a first position. The load indicatoris configured to move to a second position and engage the engagementportion when the load applied to the load-support portion exceeds afirst maximum load. The load indicator is also configured to move to thesecond position and engage the engagement portion when the load appliedto the load-support portion exceeds a second maximum load less than thefirst maximum load and when the load is positioned rearward of the loadindicator or the engagement portion. A warning indicator is coupled tothe load indicator and configured to provide an overload warning to auser in response to the load indicator moving to the second position.

Under another aspect of the invention, a load warning system has anengagement portion movable with the vehicle-support portion or the frameof a vehicle. A load indicator is coupled to the other one of thevehicle-support portion or the frame. The load indicator is spaced apartfrom the engagement portion when in a first position. The load indicatoris also configured to move to a second position and engage theengagement portion when the frame moves a selected distance relative tothe vehicle-support portion in response to the load being applied to theload-support portion. The load support portion has a switch assembly anda trigger coupled to the switch assembly. The trigger is resilientlybendable against the engagement member after the load indicator is movedto the second position. A warning indicator is coupled to the loadindicator and configured to provide an overload warning to a user inresponse to the load indicator moving to the second position.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side elevation view of a vehicle with a load warning systemin accordance with an embodiment of the present invention.

FIG. 2 is an enlarged partial schematic plan view of a load-supportportion of the vehicle of FIG. 1 with a load thereon.

FIG. 3 is an enlarged top isometric view of the load warning systemmounted on the vehicle of FIG. 1.

FIG. 4 is a partially exploded enlarged isometric view of components ofthe load warning system of FIG. 3 shown removed from the vehicle.

FIG. 5 is an enlarged isometric view of an alternate embodiment of theload warning system mountable on the vehicle of FIG. 1.

FIG. 6 is an enlarged bottom isometric view of components of analternate embodiment of the load warning system on the vehicle of FIG.1.

FIG. 7 is a schematic plan view of the load warning system on thevehicle of FIG. 1 showing wire routing along the vehicle.

FIG. 8 is an enlarged plan view of a relay assembly of the electricalcomponents of the load warning system of FIG. 1.

DETAILED DESCRIPTION

The following discussion provides a general overview of the orientationand structure of the load warning system and associated components ofone or more embodiments of the present invention. Throughout thisdisclosure, embodiments of the system are presented to display therobust nature of the device. FIG. 1 is a side elevation view of avehicle 10 that includes a load warning system 12 in accordance with anembodiment of the invention. Details of embodiments of the load warningsystem 12 are provided below. The load warning system 12 provides aneffective, simple and low-cost system to assist in maintaining safeloading conditions of the vehicle 10.

The vehicle 10 in the illustrated embodiment of FIG. 1 is a truck, suchas a pickup or flatbed truck, having a bed 16 that defines a loadsupport area. The bed 16 is mounted on a frame 17 of the vehicle, andthe frame is coupled to axles 18 and wheels 19 in a conventional mannervia a suspension system 20. The suspension system 20 allows the rearaxle 18 and the bed 16 to move relative to each other, for example, whena load 14 is placed in the bed 16 or during the operation of thevehicle. When the load 14 is placed in the bed 16, the weight of theload compresses the suspension system 20, thereby moving the frame 17relative to the rear axle 18. The heavier the load 14, the more thesuspension system 20 will be compressed and the farther the bed 16 willmove relative to the rear axle 18.

The load warning system 12 is configured to provide a warning signal toa user when the weight or the position of the load 14 in the bed 16 issufficient to compress the suspension system 20 and move the frame 17beyond a certain distance relative to the rear axle 18. The load warningsystem 12 is configured to provide a warning signal to a user when theweight of the load 14 exceeds a maximum weight, regardless of the load'sposition in the bed. The load warning system 12 is also configured to beactivated if a certain load 14, which weights less than the maximumweight rated for the vehicle, is placed toward the rear of the bed 16.The load warning system 12 can also be configured to be activated if acertain load 14 less than the rated maximum weight is placed too far toone side of the bed 16. The load warning system 10 is also configured soit is less sensitive to weight that is placed in the cab of the truck,such as when a driver gets into a vehicle after it is loaded.

FIG. 2 is a schematic plan view showing the load 14 in the bed 16 of thevehicle 10 of FIG. 1. The load 14 can be distributed in the bed 16 in avariety of positions relative to the rear axle 18 of the vehicle 10. Theposition of the load 14 in the bed 16 can determine the extent to whichthe suspension system 20 is compressed and the rear portion of the frame17 is moved relative to the rear axle 18. When the load 14 is directlyover the rear axle 18 or rearward of the axle, the suspension system 20will be compressed more and the frame 17 will move a greater distancerelative to the rear axle than when the same load is in the forwardmostposition in the bed 16. The load warning system 12 provides a warningsignal when the load causes the frame 17 to move vertically orrotationally beyond a selected distance relative to the rear axle 18.The load warning system 12 could also be used in conjunction with otherportions of the vehicle, such as the vehicle's front axle, to detecteither underloading or overloading conditions based on the movement ofthe vehicle's frame 17 relative to a selected structure coupled to thesuspension system 20.

FIG. 3 is an enlarged top isometric view of the load warning system 12shown installed on the vehicle 10 of FIG. 1 in accordance with oneembodiment of the present invention. FIG. 4 is a partially exploded,enlarged isometric view of the components of the load warning system ofFIG. 3 shown removed from the vehicle. The load warning system 12 of theillustrated embodiment includes a frame bracket 22 that mounts withconventional fasteners to the frame 17 of the vehicle 10. In theillustrated embodiment, the frame bracket 22 is mounted to the frame 17above and rearward of the rear axle 18. The frame bracket 22 is boltedor otherwise securely mounted to the frame 17 so the frame bracket moveswith the frame as a unit. The illustrated frame bracket 22 extends in acantilevered manner from the frame 17.

A switch assembly 28 is adjustably connected to a free end 26 of theframe bracket 22. The frame bracket 22 is shaped and sized to securelysupport the switch assembly 28 at a selected location and orientationrelative to the rear axle 18. In the illustrated embodiment, the switchassembly 28 is positioned rearward of the rear axle 18. The shape andsize required for the frame bracket 22 may be affected by the make andmodel of the vehicle 10 to which the load warning system 12 is beinginstalled. As an example, the frame bracket 22 shown in FIGS. 3 and 4 isshaped and sized for use on a truck manufactured by Ford, namely, atruck having the F34 cab chassis. In an alternate embodiment shown inFIG. 5, the frame bracket 22 is shaped and sized for use on GMC trucks.In other embodiments, different shapes and sizes of frame brackets 22can be used with other vehicles. In yet other embodiments, the framebracket 22 may be an integral component of the switch assembly 28.

As best seen in FIGS. 3–5, the switch assembly 28 includes a sealedhousing 30 connected to a mounting plate 31, and the mounting plate isfastened to the frame bracket 22. The sealed housing 30 contains amicroswitch 32 movable between a normal inactive position and anactivated position. The switch assembly 28 has a flexible trigger member34 connected to the microswitch 32 and sealably coupled to the housing30 so as to provide a fully protected environment for the microswitch.The microswitch 32 is moved from the normal, inactive position to theactivated position by moving the trigger member 34 in any directionperpendicular to the trigger member's longitudinal axis.

The microswitch 32 in one embodiment is configured so the microswitch isopen when in the normal, inactive position and closed when in theactivated position. In this configuration, the switch assembly 28 drawsno power when it is monitoring for overload condition. In theillustrated embodiment, the overload switch assembly 28 is awater-resistant assembly, such as the SWM 43 or 44 switch assemblymanufactured by Precor, Inc. of Boise, Id. In alternate embodiments,other switch assemblies 28 can be used, including switch assembliessimilar to the Precor switch assembly wired to be either in the“normally open” or “normally closed” position.

The mounting plate 31 extends from the sealed housing 30 and has a pairof apertures 36 that receive fasteners to connect to the free end 26 ofthe frame bracket 22. The free end 26 of the frame bracket 22 hascorresponding receiving apertures 38 that align with the apertures 36 inthe mounting plate 31. In the embodiment illustrated in FIGS. 3 and 4,the lower receiving aperture 38 in the frame bracket 22 is an elongated,arcuate slot that allows for adjustment of the angular orientation ofthe mounting bracket 31, and thus the switch assembly 28 relative to theframe 17.

In an alternate embodiment illustrated in FIG. 5, the frame bracket 22is an L-shaped bracket with an arcuate-shaped upper aperture 38 thatallows for the positional adjustment of the switch assembly 28. Theposition of the switch assembly 28 and the trigger member 34 can beadjusted as needed upon installation, maintenance, or calibration of theload warning system 12. In other embodiments, the switch assembly 28 canbe adjustably connected to the frame bracket 22 in other manners thatallow for angular or positional adjustment of the switch assemblyrelative to the frame bracket.

Once the switch assembly 28 is in the desired position relative to theframe bracket 22, the fasteners are securely tightened so as to hold theswitch assembly in the selected position. The secured frame bracket 22and the switch assembly 28 will move with the frame's cross member 24 asa unit relative to the rear axle 18, such as when the load 14 (FIG. 1)is placed in the bed 16 and the suspension system 20 is compressed.

FIG. 6 is a bottom isometric view of an embodiment of components of theload warning system 12 configured for a selected vehicle configuration.The load warning system 12 includes a second bracket 40 mounted to therear axle 18 in a position forwardly adjacent to and spaced apart fromthe trigger member 34. In the illustrated embodiment, the bracket 40 issecurely bolted at one end to a bell housing 42 of the rear axle 18 andpositioned below the trigger member 34 by a selected distance.Accordingly, the bracket 40 moves with the rear axle 18 as a unit.

The bracket 40 is cantilevered such that the bracket's free end providesan engagement portion 44 below the trigger member 34 (FIG. 6). Theengagement portion 44 is positioned so the trigger member 34 pressesagainst the engagement portion when the suspension system 20 iscompressed and the frame 17 is moved beyond a selected distance relativeto the rear axle 18. When the trigger member 34 is pressed against theengagement portion 44, the trigger member moves the microswitch 32within the sealed housing 30 from the normal, inactive position to theactivated position. Upon moving the microswitch 32 to the activeposition, a signal is generated that indicates a warning condition.

Operation of the switch assembly 28 is demonstrated when a load 14 (FIG.2) is put into the bed 16 (FIG. 2) of the vehicle 10 (FIG. 2). Thesuspension system 20 (FIG. 2) will be compressed so that the crossmember 24 and the switch assembly 28 move as a unit downwardly relativeto the rear axle 18 and the bracket 40. When the weight and/or positionof the load 14 in the bed 16 is such that the trigger member 34 movestoward the bracket's engagement portion 44 but does not press againstit, the microswitch 32 in the switch assembly 28 remains in the normal,inactive position so a warning signal is not generated.

When a load 14 in the bed 16 (FIG. 2) exceeds a maximum weight rated forthe vehicle 10, and the load is generally centered in the bed forward ofthe rear axle 18, the load causes the suspension system 20 (FIG. 2) tocompress substantially vertically. As the suspension system 20compresses, the trigger member 34 presses against the bracket'sengagement portion 44, and the microswitch 32 is moved to the activatedposition, thereby indicating an overload condition. When a load 14 isplaced in the bed 16 directly over the rear axle 18, the load cancompress the suspension system 20 so the trigger mechanism 34 engagesthe bracket's engagement portion 44 to indicate an improper loadcondition, even though the load weighs less than the maximum weightrated for the vehicle.

When a load 14 is placed in the bed 16 behind the rear axle 18, the loadwill compress the suspension system 20 vertically and also cause the bedto slightly rotate about an axis of rotation generally close to the rearaxle. As the bed rotates, the rear end of the bed drops and the frontend of the vehicle 10 can be raised. As the bed 16 rotates relative tothe rear axle 18 past a certain distance, it causes the trigger member34 to engage the bracket's engagement portion 44. Such rotational motionwill often occur when the load 14 is less than the maximum weight limitrated for the vehicle. In one embodiment, a load that is approximately70% of the rated maximum load for the vehicle can activate the loadwarning system 12 and provide the warning of an improper load condition.Therefore, the load warning system 12 provides a warning when the loadexceeds a rated maximum weight or when the weight and position of theload in the bed causes an undesirable loading condition even though theload is below the rated maximum load.

After the trigger member 34 has moved the microswitch 32 to theactivated position, the microswitch will remain in the activatedposition until the load 14 (FIG. 2) is adjusted or reduced so the switchassembly 28 moves upwardly until the trigger member 34 is lifted out ofengagement with the engagement portion 44 of the bracket 40. Themicroswitch 32 and the trigger member 34 are biased or otherwise urgedtoward the normal, inactive position. After the trigger member 34 islifted from the engagement portion 44, the microswitch 32 returns to thenormal, inactive position.

In the illustrated embodiments, the switch assembly 28 is activated byengaging the bracket 40. In alternate embodiments for use on selectedvehicles, the switch assembly 28 may be configured and positionedadjacent to another structure on the vehicle 10, so that the triggermember 34 will move into engagement with that structure when a load isapplied to the vehicle. The trigger member 34 will then trip themicroswitch 32 so as to generate a warning signal indicating theimproper load condition.

In another alternate embodiment, the switch assembly 28 may be mountedat another location on the vehicle 10 such that the frame 17 will moverelative to the other location when a load 14 is applied to the vehicle.For example, the switch assembly 28 could be mounted to the frontportion of the vehicle's frame 17 adjacent to the front axle, so thetrigger member 34 is below an engagement structure. If the vehicle 10 isloaded such that the front of the vehicle's frame 17 is lifted upwardlyrelative to the front axle, the upward movement of the frame will bringthe trigger member 34 into engagement with the engagement portion 44 ofthe bracket 40, thereby moving the microswitch 32 to the activatedposition to indicate an overload or underload configuration.Accordingly, the load warning system 12 is very effective when applyinga load 14 to the bed 16 of a vehicle 10, as well as when other loads areapplied to the vehicle's frame 17, such as via a trailer or the like.

As best seen in FIGS. 5 and 6, the trigger member 34 is an elongatedflexible member that can resiliently bend when pressed with sufficientforce against the bracket 40. The trigger member 34 of the illustratedembodiment is an elongated, tightly wound coil spring coupled to themicroswitch 32. The microswitch 32 has a very small dead band (i.e., therange of motion before the microswitch moves to the activated position),so that the microswitch can be moved to the activated position when afairly small force is exerted against the trigger member 34.

The flexible trigger member 34 has sufficient stiffness so it will notsubstantially bend or deflect before the microswitch 32 is moved to theactivated position. If, however, the movement of the vehicle's frame 17relative to the rear axle 18 is extreme, so that the trigger member 34is pressed hard against the bracket's engagement portion 44, the triggermember will resiliently bend so as to prevent extreme forces beingapplied directly to the microswitch 32. Further, when the vehicle 10(FIG. 2) is in operation and encounters significant impact to thesuspension system 20 (FIG. 2), such as by hitting a large bump or pothole, the flexible trigger member 34 can hit and bend against theengagement portion 44 and then return to its original position, therebyprotecting the switch assembly 28 from damage. Accordingly, the switchassembly 28 is a simple, rugged, and weather-resistant assembly.

As best seen in FIGS. 4 and 5, the switch assembly 28 has an electricalcable 50 extending through the housing 30 and connected at one end tothe microswitch 32. A seal is provided between the electrical cable 50and the housing 30 to maintain the sealed environment in the housingaround the microswitch 32. In one embodiment, the electrical cable 50has a pair of mating connectors 60 and 62 (FIG. 7) releasably connectedto each other adjacent to the switch assembly 28. In one embodiment, ashort length of heat-shrink tubing is provided over both connectors 60and 62.

FIG. 7 is a schematic view showing the electrical cable 50 routed alongselected portions of the vehicle 10 and connected to the vehicle'selectrical center 54. In one embodiment, the electrical cable 50 extendsfrom the switch assembly 28 and is routed along the existing vehicle'swire bundles, such as along the driver's side. The electrical cable 50is secured to the vehicle's wire bundles using conventional wire ties orother conventional securing mechanisms.

The end of the electrical cable 50 opposite the switch assembly 28 isattached to a relay assembly 52 that connects to the electrical center54. The relay assembly 52 is coupled to a warning indicator 55.Accordingly, when an improper load condition exists and the triggermember 34 causes the microswitch 32 to move to the activated position,the signal generated from the microswitch is provided to the relayassembly 52. The relay assembly 52 provides a signal to the electricalcenter 54 so as to activate the warning indicator 55 so as to provide anaudible and/or visual warning to the user that the improper loadcondition has occurred.

In one embodiment, the relay assembly 52 is connected to the electricalcenter 54 so as to activate an audible warning indicator 55, such as thevehicle horn or an auxiliary horn, that generates a sound indicatingthat an improper load condition exists. The audible warning indicator 55will continue to sound until the load is lessened or shifted so as tomove the microswitch 32 back to the normal, inactive position. In analternate embodiment, a visual warning indicator, such as flashingvehicle lights or an auxiliary warning light, will appear to indicatethat an improper load condition exists. In yet another alternateembodiment, both audible and visual warning indicators can be used.

As best seen in FIG. 8, the relay assembly 52 includes two relays 64 and66 mounted on a mounting plate 68. The first relay 64 connects to thevehicle's start relay in the electrical center 54 (FIG. 7), and thesecond relay 66 connects to the vehicle's horn relay, also in theelectrical center. The relay assembly 52 is configured so that, when theswitch assembly 28 (FIG. 7) is activated, the vehicle's horn will sounduntil the improper load condition has been corrected. The second relay664 is configured so the load warning system 12 (FIG. 7) will onlyprovide the audible warning signal, e.g., sounding the vehicle's horn,when the vehicle is in park or neutral. If the vehicle 10 is in reverseor any drive gear, the load warning system 12 will not sound the horn ifan improper load condition exists. When the vehicle 10 is being drivenand it hits a large bump, the load warning system 12 of the illustratedembodiment will not sound the horn.

As indicated above, the load warning system 12 draws no power when inthe normal, inactive position, such that there is no drain on thevehicle's battery, and no current flows through the starter relay unlessthe ignition key activates the starter. Accordingly, the load warningsystem 12 of the illustrated embodiment has no separate ON/OFF switch,no lights to manually turn on or off, and nothing for the operator to doexcept to reduce or shift the load 14 on the vehicle 10 when the loadwarning system 12 indicates an improper load condition has occurred.

In an alternate embodiment of the invention, the relay assembly 52 canbe coupled to a different audible warning device, such as an alarm, orto a visible warning indicator mechanism, such as a warning light or thelike. In another embodiment, the load warning system can bypass thestarter relay, and the system includes a data processor 80 (shown inphantom lines in FIG. 7) operatively coupled to the switch assembly 28.The processor 80 is configured to provide continual monitoring of theswitch assembly 28 to determine the frequency and/or duration of timethat the microswitch 32 is in the activated position while the vehicleis stationary or being driven. When a selected condition exists, such asa number of activations over a selected period or specified duration oftime that the microswitch 32 remains in the activated position, theprocessor 80 will provide a signal to activate the warning indicator 55.In this embodiment, if the vehicle 10 is in motion and the triggermember 34 is occasionally activated because of road disturbances, theprocessor 80 will be able to identify these occasional activationswithout activating the warning indicator 55. If, as an example, the load14 in the vehicle 10 shifts during transportation, thereby resulting insubstantially continuous activation of the microswitch 32 to indicate animproper load condition, the processor 80 would detect the change and awarning signal would be provided to the user that an improper loadcondition exists.

When the load warning system 12 is installed on the vehicle 10 either asoriginal equipment or as a retrofit, the system is calibrated to providea warning signal when the load exceeds a selected maximum load. The loadwarning system 12 can be easily and quickly calibrated by placing aknown maximum load 14 into the bed 16 of the vehicle 10 at a selectedlocation and then adjusting the position of the switch assembly 28relative to the bracket 40. In one embodiment shown in FIG. 2, thecalibration load 14 is 3,000 pounds±30 pounds. The load 14 has afootprint of approximately 30″×30″, and the load is placed so the load'scenter is approximately 26″±3″ behind the front of the bed 16. The load14 is centered laterally within approximately 2″ of the vehicle'scenterline.

As best seen in FIG. 3 from under the vehicle 10, the fastenersconnecting the switch assembly 28 to the frame bracket 22 are thenloosened. The switch assembly 28 is then rotated until the triggermember 34 contacts the engagement portion 44 of the bracket 40 justenough so that the microswitch 32 moves to the activated positionthereby sounding the horn. The switch assembly 28 is then secured inthis position relative to the frame bracket 22, so as to be in a finalcalibrated position. After the switch assembly 28 is secured in thefinal calibration position, a person should be able to push upwardly ona portion of the frame 17 rearward of the rear axle 18 enough to causethe trigger member 34 to move the microswitch 32 back to the normal,inactive position.

The configuration of the load warning system 12 on the vehicle 10 asdiscussed above is such that the location of the measurement pointdetermines how the system will react as the center of gravity of theload 14 is moved around on the bed 16 or other load support area of thevehicle. The load warning system 12 is configured to minimize the effectof a driver's weight. The load warning system 12 of the illustratedembodiment is also configured to generate the warning signal in theevent a reduced load, such as approximately 70% of the maximum load, isplaced too far rearward in the bed 16 of the vehicle 10. In thisconfiguration, the reduced load will cause the compression of thesuspension system 20 and rotation of the frame 17 relative to the rearaxle 18, thereby indicating an improper load configuration. In thisoverload configuration, the load rearward of the rear axle 18 can causethe forward portion of the vehicle's frame 17 to lift so as to reducethe weight on the vehicle's front wheels, thereby resulting in theoverload condition at the rear end and an undesirable underloadcondition at the forward end of the vehicle.

After the load warning system 12 is calibrated, the calibration load isremoved from the bed 16 and the vehicle 10 can be used in regularoperation. The load warning system 12 can be easily recalibrated asneeded, for example, if the vehicle's suspension system 20 relaxes orsoftens over time. The load warning system 12 can also be easily andquickly tested by reaching under the vehicle 10 and manually moving thetrigger member 34 to confirm that the warning signal will be generatedin an improper load condition. If any system components have beendamaged, or require replacement or maintenance, such as the microswitch32, the flexible trigger member 34, the brackets 22 and 40, theelectrical cable 50 or the like, the component can be quickly and easilyremoved and replaced, thereby minimizing the amount of time the vehicleis out of service.

In one embodiment, the load warning system 12 includes a data collector70, shown schematically in FIG. 7, operatively connected to the vehicle10 and to the switch assembly 28. The data collector 70 is configured tocollect data during operation of the vehicle, and the data can bedownloaded or otherwise output for analysis. The data collector 70 canbe configured to collect and output data, including, for example, thetime, date and duration of operation, or the frequency or duration ofactivation of the switch assembly. The data collector 70 can also beconnected to a conventional load cell (not shown) to collect and outputdata about the weight of the load(s) applied to the vehicle 10.

The data from the data collector 70 can then be used in any number ofways, including determining when routine maintenance may be needed forthe load warning system 12. If the vehicle is a rental vehicle, the datacollector 70 could be used to determine whether conditions existedduring operation that justifies different charges or costs to the renterof the vehicle. Accordingly, the load warning system 12 can be used formore than just determining if an improper load condition exists.

From the above detailed description, it will be appreciated thatspecific embodiments of the invention are described herein for purposesof illustration, but that various modifications may be made withoutdeviating from the spirit and scope of the invention.

1. A vehicle and load warning system, comprising: a vehicle having aload-support portion adapted to receive a load thereon, a frame coupledto the load-support portion, and a vehicle-support portion coupled tothe frame, the frame being movable relative to the vehicle-supportportion; an engagement portion movable with one of the vehicle-supportportion or the frame; a load indicator coupled to another one of thevehicle-support portion or the frame, the load indicator spaced apartfrom the engagement portion when in a first position and configured tomove to a second position and engage the engagement portion when theframe moves a selected distance relative to the vehicle-support portionin response to the load being applied to the load-support portion, theload indicator having a sensor assembly and a trigger coupled to thesensor assembly, the trigger being resiliently bendable against theengagement portion after the load indicator is moved to the secondposition; and a warning indicator coupled to the load indicator andconfigured to provide a warning to a user in response to the loadindicator moving to the second position.
 2. The system of claim 1wherein the engagement portion is at least a portion of a bracketattached to the one of the vehicle-support portion or the frame.
 3. Thesystem of claim 1 wherein the frame is rotatable relative to the vehiclesupport about an axis of rotation when the load is rearward of the axisof rotation, and at least one of the engagement portion and the loadindicator is positioned rearward of the axis of rotation.
 4. The systemof claim 1 wherein the vehicle support portion includes a rear axleassembly, and at least one of the engagement portion and the loadindicator is mounted to the rear axle assembly, and the other ofengagement portion and the load indicator is positioned generallyrearward of the rear axle assembly.
 5. The system of claim 1 wherein theload indicator includes a mounting bracket attached to the other one ofthe vehicle-support portion or the frame, and the sensor assembly isadjustably attached to the mounting bracket.
 6. The system of claim 1wherein the vehicle has a power source, the load indicator is coupled tothe power source and draws power from the power source only when theload indicator is in the second position.
 7. The system of claim 1,further comprising a data collector coupled to the vehicle andconfigured to collect and output data including at least one of time,date, load, activation of the warning indicator, and duration of use ofthe system.
 8. The system of claim 1 wherein the warning is an audiblewarning.
 9. The system of claim 1 wherein the warning indicator is avisual overload indicator.
 10. The system of claim 1 wherein the warningindicator includes a horn, and the signal from the load indicatoractivates the horn to provide the warning to the user.
 11. The system ofclaim 1 wherein the vehicle has an electrical control with a starterrelay, and further comprising a relay assembly coupled to the loadindicator and to the starter relay.
 12. The system of claim 11 whereinthe relay assembly is configured to allow for generation of the warningwhen the vehicle is in a park or neutral gear condition.
 13. The systemof claim 1, further comprising a control system coupled to the loadindicator and to the warning system, the control system being configuredto monitor a frequency or duration of the signals from the loadindicator and to block the signal from reaching the warning indicatoruntil a selected condition of frequency or duration of the signalsexists.
 14. The system of claim 1 wherein the load-support portion ofthe vehicle is a rear axle coupled to the frame by a suspension system.15. The system of claim 1 wherein the sensor assembly includes a housingand a switch in the housing, the switch being coupled to the trigger.16. A vehicle and load warning system, comprising: a vehicle having aload-support portion adapted to receive a load thereon, a frame coupledto the support portion, and a vehicle-support portion coupled to theframe, the frame being vertically movable relative to the vehiclesupport portion and being rotatable about a point of rotation relativeto the vehicle support portion; an engagement portion movable with oneof the vehicle-support portion or the frame; a load indicator coupled toanother one of the vehicle-support portion or the frame, the loadindicator spaced apart from the engagement portion when in a firstposition and configured to move to a second position and engage theengagement portion when the frame moves vertically and rotationally aselected distance relative to the vehicle-support portion in response tothe load being applied to the load-support portion, the load indicatorhaving a sensor assembly and a trigger member coupled to the sensorassembly, the sensor assembly is spaced laterally apart from theengagement portion so as to be out of vertical alignment with theengagement portion, at least a portion of the trigger member is invertical alignment with the engagement portion and being directlyengagable with the engagement portion; and a warning indicator coupledto the load indicator and configured to provide a warning to a user inresponse to the load indicator moving to the second position.
 17. Thesystem of claim 16 wherein the engagement portion is at least a portionof a bracket attached to the one of the vehicle-support portion and theframe.
 18. The system of claim 16 wherein the sensor assembly includes aswitch and the trigger is a flexible trigger member coupled to theswitch and resiliently bendable against the engagement member after theload indicator is moved to the second position.
 19. The system of claim16 wherein the load indicator includes a mounting bracket attached tothe other one of the vehicle-support portion or the frame, and thesensor assembly is adjustably attached to the mounting bracket.
 20. Thesystem of claim 16 wherein the warning is an audible or visual warning.21. The system of claim 16 wherein the vehicle has an electrical controlwith a starter relay, and further comprising a relay assembly coupled tothe load indicator and to the starter relay.
 22. The system of claim 21wherein the relay assembly is configured to allow for generation of thewarning when the vehicle is in a park or neutral gear condition.
 23. Thesystem of claim 16, further comprising a control system coupled to theload indicator and to the warning system, the control system beingconfigured to monitor a frequency or duration of the signals from theload indicator and to block the signal from reaching the warningindicator until a selected condition of frequency or duration of thesignals exists.
 24. The system of claim 16 wherein the load-supportportion of the vehicle is a rear axle coupled to the frame by asuspension system.
 25. The system of claim 16 wherein the vehicle has apower source, the load indicator is coupled to the power source anddraws power from the power source only when the load indicator is in thesecond position.
 26. The system of claim 16, further comprising a datacollector coupled to the vehicle and configured to collect and outputdata including at least one of time, date, load, activation of thewarning indicator, and duration of use of the system.
 27. The system ofclaim 16 wherein the sensor assembly includes a housing and a switch inthe housing, the switch being coupled to the trigger.
 28. A vehicle andload warning system, comprising: a vehicle having a load-support portionadapted to receive a load thereon, a frame coupled to the supportportion, and a vehicle-support portion coupled to the frame, the framebeing movable relative to the vehicle support portion; an engagementportion movable with one of the vehicle-support portion or the frame; aload indicator coupled to another one of the vehicle-support portion orthe frame, the load indicator spaced apart from the engagement portionwhen in a first position and configured to move to a second position andengage the engagement portion when the load applied to the load-supportportion exceeds a first maximum load, and the load indicator isconfigured to rotate and move vertically relative to the another one ofthe vehicle support or the frame to the second position and engage theengagement portion substantially along a point contact when the loadapplied to the load-support portion exceeds a second maximum load lessthan the first maximum load and the load is positioned rearward of theat least one of the load indicator and the engagement portion; and awarning indicator coupled to the load indicator and configured toprovide a warning to a user in response to the load indicator moving tothe second position.
 29. The system of claim 28 wherein the vehicle hasa power source, the load indicator is coupled to the power source anddraws power from the power source only when the load indicator is in thesecond position.
 30. The system of claim 28 wherein the load indicatorincludes a switch and a flexible trigger member coupled to the switchand resiliently bendable against the engagement member after the loadindicator is moved to the second position.
 31. The system of claim 28wherein the warning is an audible or visual warning.
 32. The system ofclaim 28 wherein the vehicle has an electrical control with a starterrelay, and further comprising a relay assembly coupled to the loadindicator and to the starter relay.
 33. The system of claim 32 whereinthe relay assembly is configured to allow for generation of the overloadwarning when the vehicle is in a park or neutral gear condition.
 34. Thesystem of claim 28, further comprising a control system coupled to theload indicator and to the warning system, the control system beingconfigured to monitor a frequency or duration of the signals from theload indicator and to block the signal from reaching the warningindicator until a selected condition of frequency or duration of thesignals exists.
 35. A load warning system for use with a vehicle havinga load-support portion adapted to receive a load thereon, a framecoupled to the load-support portion, and a vehicle-support portionmovably coupled to the frame, comprising: an engagement portionmountable to one of the vehicle-support portion or the frame and beingmovable with the one of the vehicle-support portion or the frame as aunit; a load indicator mountable to another one of the vehicle-supportportion or the frame, the load indicator spaced apart from theengagement portion when in a first position and configured to move to asecond position and engage the engagement portion when the frame moves aselected distance relative to the vehicle-support portion in response tothe load being applied to the load-support portion, the load supportportion having a switch assembly and a trigger coupled to the switchassembly, the trigger being resiliently bendable against the engagementmember after the load indicator is moved to the second position; and awarning indicator coupled to the load indicator and configured toprovide an overload warning in response to the load indicator moving tothe second position.
 36. The system of claim 35 wherein the engagementportion is at least a portion of a bracket mounted on the one of thevehicle-support portion and the frame.
 37. The system of claim 35wherein the load indicator is connectable to a power source and drawspower from the power source only when the load indicator is in thesecond position.
 38. The system of claim 35 wherein the load indicatorincludes a sealed housing, a switch in the sealed housing, and aflexible trigger resiliently bendable against the engagement memberafter the load indicator is moved to the second position.
 39. The systemof claim 35 wherein the overload warning is an audible or visualwarning.
 40. The system of claim 35 wherein the warning indicatorincludes at least one of an audible indicator and a visual indicator.41. The system of claim 35 wherein the vehicle has an electrical controlwith a starter relay, and further comprising a relay assembly coupled tothe load indicator and to the starter relay, the relay assemblyconfigured to allow for generation of the overload warning when thevehicle is in a park or neutral gear condition.
 42. The overload warningsystem of claim 35, further comprising a control system coupled to theload indicator and to the overload warning system, the control systemconfigured to monitor at least one of the frequency or duration of thesignals from the load indicator and to block the signal from reachingthe overload warning indicator until a selected condition of frequencyor duration of the signals exists.
 43. The system of claim 35 whereinthe sensor assembly includes a housing and a switch in the housing, theswitch being coupled to the trigger.
 44. A load warning system for usewith a vehicle having a load-support portion adapted to receive a loadthereon, the vehicle having a first portion coupled to the load-supportportion and a second portion movable relative to the first portion uponapplication of a selected load on the load-support portion, comprising:an engagement portion movable with the one of the vehicle-supportportion or the frame; a load indicator coupled to another one of thevehicle-support portion or the frame, the load indicator spaced apartfrom the engagement portion when in a first position and configured tomove to a second position and engage the engagement portion when theload applied to the load-support portion exceeds a first maximum load,and the load indicator is configured to rotate and move verticallyrelative to the another one of the vehicle support or the frame to thesecond position and engage the engagement portion substantially along apoint contact when the load applied to the load-support portion exceedsa second maximum load less than the first maximum load and the load ispositioned rearward of the at least one of the load indicator and theengagement portion; and a warning indicator coupled to the loadindicator and configured to provide a warning to a user in response tothe load indicator moving to the second position.
 45. The system ofclaim 44 wherein the engagement portion is a bracket adjustably mountedon the one of the first or second portions.
 46. The system of claim 44wherein the load indicator includes a trigger resiliently bendableagainst the engagement member after the load indicator is moved to thesecond position.
 47. The system of claim 44 wherein the load indicatorincludes a mounting bracket and a switch assembly adjustably attached tothe mounting bracket.
 48. The system of claim 44, further comprising acontrol system coupled to the load indicator and to the warningindicator, the control system being configured to monitor the frequencyor duration of the signals from the load indicator and to block thesignal from reaching the warning indicator until a selected condition offrequency or duration of the signals exists indicating an overloadcondition.
 49. A vehicle and overload warning system, comprising: avehicle having a power source, an electrical control with a starterrelay, a load-support portion adapted to receive a load thereon, a firstportion coupled to the support portion, and a second portion movablerelative to the first portion upon application of the load on theload-support portion; an engagement portion connected to one of thefirst or second portions; a load indicator coupled to the power sourceand connected to another one of the first or second portions, the loadindicator spaced apart from the engagement portion and in a firstposition when the load on the load-support portion is less than amaximum load, and the load indicator being configured to engage theengagement portion and to move to a second position when the load on theload-support portion is greater than the maximum load, the loadindicator drawing power from the power source when in the secondposition and drawing no power from the power source when in the firstposition; a warning indicator coupled to the load indicator andconfigured to provide a warning to a user in response to the loadindicator moving to the second position; and a relay assembly coupled tothe load indicator and to the starter relay; the relay assembly beingconfigured to allow for generation of the warning when the vehicle is ina park or neutral gear condition.
 50. The system of claim 49 wherein theload indicator is a sensor assembly having a trigger resilientlybendable against the engagement member after moving to the secondposition.
 51. The system of claim 49 wherein the load indicator isadjustably mounted to the other one of the first and second portions ofthe vehicle.
 52. The system of claim 49 wherein the warning indicatorgenerates at least one of an audible overload warning or a visibleoverload warning.